Rotary printer units for intermittent and random dyeing



United States Patent [72] Inventor Roy L. Keown La Grange, Georgia [21] Appl. No. 852,967 [22] Filed Aug. 11, 1969 Continuation of Ser. No. 575,869, Aug. 29, 1966, abandoned.

Nov. 24, 1970 Varicolor, Inc.,

a corporation of Georgia [45] Patented [73] Assignee [54} ROTARY PRINTER UNITS FOR INTERMITTENT AND RANDOM DYEING 6 Claims, 4 Drawing Figs.

Primary Exam iner-Robert E. Pulfrey Assistant Exam inerJ Reed Fisher Attorney-Walter M. Rodgers ABSTRACT: For applying a dye of a single color to a plurality of strands of yarn, a pair of movable printer units are arranged so as to intermittently engage and dye the strands. A drive imparts rotative movement to both printer units and a separate coupling is interconnected between said drive and each of said printer units. A control is interrelated with each coupling and effective to impart relative movement to the printer units whereby the spacing between dyed portions of the strands is varied. The control is preferably interconnected with the drive so that all printer units are coordinated with each other. Preferably the printer units are arranged in coaxial relationship to each other and are arranged to rotate about their common axes with the yarn to be dyed disposed immediately adjacent to the perimeter of the printer units and movable in synchronism therewith, the printer units being angularly shiftable relative to each other while rotating so as constantly to vary the spacing between printer elements or bars located on each printer unit and the printer elements or bars located on the other printer unit. More than one pair of printer units may be used to apply dyes ofmore than one color.

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INVILNI'UA. ROY L. KEOWN ATTORNEY Patented Nov. 24, 1970 Sheet 3 of 4 INVIL NTUR. ROY KEOWN m ATTORNEY Patented (W. 24,

INVIi/VTOR.

ROY L. KEOWN 77/, 4

I ATTORNEY Sheet INVIiN'IUR. ROY L. KEOWN pllh Sheet of 4 FIG. 5

FIG 6 Patented Nov. 24, 1970 ATTORNEY ROTARY PRINTER UNITS FOR INTERMITTENT AND RANDOM DYEING This is a continuation application of Ser. No. 575869, filed Aug. 29, 1966, now abandoned.

This invention relates to dyeing apparatus and more particularly to a machine for applying dye to yarn fiber and the like in such a way that the spacing between adjacent dyed areas is varied in a diverse and random fashion.

Certain textile products such as carpets, for example, are

made by looping strands of yarns through a sheet of material such as might be woven from jute and the like. Where the yarn is dyed with dye which is spaced along the length thereof. the finished carpet may incorporate undesirable repetitions of pattern which frequently are objectionable from the standpoint of ap earance. Of course, if the spacing between adjacent dyed areas is varied sufficiently, the finished effect of the carpet will be uniform throughout its area and the appearance thereof will be homogenous and attractive.

A principle object of this invention is to provide apparatus for dyeing strands of yarn and the like in a manner such that the spacing betweenadjacent dyed areas is varied sufficiently so as to prevent undesirable repetition and concentration of colors in the finished product made from the strands of yarn.

Another object of this invention is the provision of an improved yarn dyeing machine which is arranged so as automatically to apply dye of a plurality of colors in a random spaced fashion and which is adaptable for applying a base color to the yarn which completely dyes the yarn initially and to which other colors may be added in spaced relation.

Still another object of the invention is to provide an improved yarn dyeing machine which applies dye to the yarn in a constantly variable space pattern over a substantial length of yarn and which in addition is adaptable for use in conjunction with several colors.

Another object of the invention is to increase the speed of dyeing ofyarn. 7

Still another object of the invention is to achieve the desired spacing and precision oflocation of dyed areas.

For a better understanding of the invention reference may be had to the following detailed description taken in conjunction with the accompanying drawings in which -FIG. 1 is a side view of a dyeing machine constructed in accordance with the invention; FIG. 2 is a plan view of the apparatus depicted in FIG. 1; FIG. 3 is an enlarged sectional view taken along the line designated 3-3 in FIG. 2; FIG. 4 is a cross-sectional view taken along the line designated 4-4 in FIG. 3; FIG. 5 is a crosssectional view taken along the line designated 5-5 in FIG. 2; FIG. 6 is a simplified schematic view of a pair of printer elements constructed according to the invention; and in which FIG. 7 is an enlarged perspective view corresponding generally to the arrangement shown in FIG. 6.

With reference to the drawings the numeral I generally designates a source'of strands of fiber to be dyed and may comprise a plurality of cones or spools mounted on a creel from which individual strands of fiber are fed through a system of rollers generally designated at 2 and into a mechanism generally designated at 3 for applying a solid color throughout the length ofthe strand fed from creel 1. The numerals 4 and 5 generally designate dyeing apparatus constructed in accordance with this invention and arranged to apply dye to the strands which have completed their passage through mechanism 3, one color being applied'by the mechanism designated generally at 4 and another color being applied by the mechanism generally designated by the numeral 5. The mechanisms designated by the numerals 3, 4 and 5 are driven by driving means including an electric motor 6 which is directly coupled to a variable speed unit and speed reducer schematically depicted at 7 which in turn by way of a belt or chain drive 8 is arranged to impart operating movement to.

gear boxes 9, l0 and 11 which are interconnected by shaft 12.

The mechanism is mounted on a frame comprising upright elements l3, I4, 15 and I6 and horizontal frame members l7, l8, and 19.

The strands to be dyed and which are collectively or individually referred to and designated by the letter Y are fed out of the right hand end of the machine as depicted in FIG. 1 and into a suitable dye setting, washing and drying mechanism which may be of conventional construction following which the dried strands are accumulated in any desired fashion such as by way of cones, beams and the like.

The mechanism designated generally by the letter 3 simply applies a solid color dye throughout the length of the strands to be dyed and which are designated at Y. This mechanism comprises a vat designated by the numeral 20 and which contains a supply of dye. The yarn Y is fed underneath a roller 21 rotatably mounted on a vertically disposed rod 22, a stud 23 'being fixedly mounted to the rod 22 and arranged to underlie the yarn Y. The position of rod 22 is determined by a fluid motor 24 which simply determines the elevation of the roller 21 and of the stud 23 and thereby determines the elevation of the strands Y as they enter the mechanism 3. The term fluid motor is used to denote a cylinder and its associated piston to which a pneumatic'pressure is applied. It will be understood however that other means could be employed.

Strands Y are then passed over a squeeze roll designated by the numeral 25 which is rotatable about a shaft 26 mounted on the frame ofthe machine and which is rotated by a chain drive 27 rotated by shaft 28 driven from the driving means 6 through the gear box 11 and the associated apparatus,. as shown in FIG. 2.

For the purpose of pressing the strands Y downwardly and into firm engagement with the squeeze roll 25, a presser drum 29 is mounted on shaft 30 and rotatable thereabout and driven from shaft 28 and chain 31. As is apparent from FIG. I, downward pressure on drum 29 is exerted by fluid motor 32 through vertically disposed plungers 33 and associated apparatus.

Thus the strands Y upon leaving the mechanism 3 are completely covered with dye of the color of the dye in vat 20. The strands Y then enter the random spacing apparatus designated generally at 4. Since the spaced dyeing mechanismsgenerally designated at 4 and 5 are identical, 3 description of only one such mechanism is deemed to be sufficient. Since FIGS. 3, 4 and 5 are all referenced to dyeing unit 4, the description will be in connection with that unit.

With reference to FIG. 3, a vat 34 is provided with liquid dye of any desired color and a pickup roll 35 is partially im mersed in the dye contained in vat 34. Pickup roll35 is rotatable about a shaft 36 which is journaled in the frame of the machine and to which a sprocket or gear wheel 37 is affixed. Shaft 36 and sprocket 37 are rotated in a clockwise direction by an endless chain 38 driven from sprocket 39 affixed to shaft 40. Shaft 40 as is apparent in FIG. 2 is driven from gear box 10. Thus as the pickup roll 35 rotates, a continuous film of dye is deposited about its periphery and along its length.

For the purpose of assuring uniform thickness of the dye film on pickup roll 35, a so called doctor blade 41 is affixed to the frame and in razor like fashion scrapes the dye film on the pickup roll 35 to auniform thickness in known manner.

In order to impart random sidewise and up-and-down motion to the strands of yarn Y as they approach the pickup roll 35, a so-called scrambler rod is mounted as indicated at 42 and is rotated by sprocket 43 mounted on shaft 44 journaled to the frame of the machine. The ends 42A of scrambler rod 42 are journaled for rotation in suitable fixed bearings and define the axis of rotation of the rod 42. Transverse or zigzag portions 428 and 42C engage the strands at random and apply secured to the frame ofthe machine as best shown in FIG. 3. Further control of the strands of yarn is effected by fixed control rod 49 over which the strands of yarn ride after they leave the pickup roll 35 and associated apparatus.

While a particular portion of the yarn is disposed immediately above the pickup roll 35, an application of dye is made thereto by printer elements 50, 51, 52, 53, 54 and 55 which are rotatably mounted on printer units disposed about shaft 56 which is secured to the frame of the machine and each of which could comprise one or more printing pads such as indicated in FIG. 3 at 51a and a rigid support element such as lb.

Random spacing is achieved by the printer bars 50-55 in accordance with this invention as shown in FIGS. 2, 3, 4, 5, 6 and 7. More specifically a driving head 57 is affixed to a driving sprocket 58 driven by coupling means which may take the form of an endless element 59 driven by sprocket 60 affixed to shaft 40. The printer elements or bars 50, 51 and 52 are affixed to driving head 57 in any suitable manner such as by screws 61 at one end and at the other end printer bars 50, 51, and 52 are secured to idler heads 62 by any suitable means such as by screws 63. Thus as coupling element 59 drives sprocket 58, driving head 57 rotates and with it the printer bars 50, 51, and 52 and idler head 62 and caused to rotate in a counterclockwise direction accommodating movement from left to right of the strands of yarn Y. Of course each printer element or bar 50, 51, and 52 when such element reaches its lowermost position forces the adjacent part of strands Y into contact with the pickup roll 35 and thus causes an application of dye to be made at that point.

A second printer unit is also associated with the printer unit just described and comprises the elements or bars 53, 54 and 55 which are affixed at the right hand end as viewed in FIG. 6 to driving head 64 by screws 65. Driving head 64 is rotated by a sprocket 66 which is driven by coupling means 67 which in turn is driven by a sprocket 68 mounted on and rotatable with the shaft 40. Of course it will be understood that coupling means 67 is identical to coupling means 59. The left hand ends of printer bars 53, 54 and 55 are secured to an idler head 69 by screws 70 as best shown in FIG. 6.

From the description thus far it is obvious that the endless elements 59 and 67 and associated mechanism impart rotary movement to the printer'elements or bars 50-55 to cause those elements to move in a counterclockwise direction about the shaft 56 as a center.

In order to vary the spaced relationship between the printer bars such as 50, 51 and 52 of one printer unit relative to the printer bars such as 53, 54, and 55 ofanother printer unit and v in accordance with this invention, control means are provided for engaging the driving reach 71 and the return reach 72 of each endless element 59 and 67. More specifically and as'best shown in FIG. 4 a control block 73 is mounted for vertical reciprocation within fixed channels 74 and 75. Control block 73 is moved up and down by a'vertically disposed plunger 76 to the upper end of which an eccentric 77 is mounted. Eccentric 77 cooperates with a transversely disposed shaft 78 rotated by a beveled gear 79 affixed to one end thereof which in turn is driven by a cooperating beveled gear 80 driven by shaft 81, gear 82 affixed thereto which cooperates with gear 83 and a gear box in the form ofa reducer drive 85 a sprocket 86 a chain 87 and a sprocket 88 affixed to shaft 40. Eccentric 77 may comprise a disc 77a eccentrically mounted on and integral with shaft 78 and an opening 77b formed in a collar disposed about disc 77a and in which disc 77a is rotatable, the ends of shaft 78 being rotatable in bearings affixed to the frame of the machine. Thus as shaft 40 rotates a control block 73 reciprocate up and down in accordance with the action of the eccentrics 77 and shaft 78.

Up and down movement of each control block 73 is translated into control action with respect to the driving reach 71 and the return reach 72 of the coupling means 59 by a pair of follower elements which may constitute sprockets 89 and 90 which are rotatably mounted about suitable bearings secured to the control block 73. Thus with the shaft 40 and sprocket 6i rotating at a constant speed in a counterclockwise direction, downward movement of control block 73 tends to straighten the return reach 72 of the coupling means 59 and tends to increase the driving reach 71 of the coupling means 59. This action effectively imparts motion to sprocket 58, driving head 57, and printer bars 50, 51, and 52 which is relative to drive shaft 40, sprocket 60, printer bars 53, 54, 55, driving head 6%, sprocket 66 and parts associated therewith. Of course it will be understood that coupling element 67 at the other side of the machine is simultaneously effected by rotation of shaft 78, Simultaneous movement of coupling means 67 and of the control bar 73 associated therewith does not precisely accompany movement of coupling means 59 due to the fact that the setting of the control block 73 which is associated with coupling means 57 is different from the setting of control block 73 associated with coupling means 59. Thus operation ofthe eccentric imparts different motion to the control blocks and their associated coupling means 59 and 67 whereby the spacing between printer elements 50, 51 and 52 is constantly changed with respect to the printer bars or elements 53, 54 and 55. in this manner the spacing between applications of dye to the strands of yarn Y is constantly being varied and is being repeated only after a substantial length of strands Y has been completely passed through the printer ele ment 4. Thus by the means described and in accordance with this invention,-spacing of the dyed areas of the yarn is varied so thoroughly that undesired repeat coincidences of colors in the finished product such as a carpet is completely avoided. it will be understood that an eccentric at one side ofthe machine could be eliminated if desired in which case the printer unit associated with such eccentric would simply rotate in accordance with operation of the driving element. Of course the random spacing is due in part to the changes in relative motion ofthe printer bars 50,51 and 52 relative to the printer bars 53, 54 and 55 as well as to the action of the so-called scrambler unit 42.

It is apparent that by the invention the diameter of each printer unit is but a fraction of the required diameter of a printer unit having thereon printer elements affixed in spaced relation. Stated otherwise a pattern of spacing relationships is repeated only after a substantial linear yardage of yarn is processed through the system.

Furthermore the reduction is size in the diameter of th printer units as compared with a much larger unit having fixedly spaced printer elements thereon, results in a greater angle of approach of the yarn to each printing pad. For this reason the yarn may be held out of contact with the pickup roll until forced into contact therewith by a printing pad. in this manner the precision of dye application is greatly improved.

Furthermore speed of operation is greatly increased by the invention due in part at least to the fact that all operating elements are movable without any sudden changes in direction or velocity. By the same token the rate at which yarn may be dyed is greatly increased by the invention thereby substantially increasing production over presently known systems.

It will be understood that a different color dye would be placed in vat 34 associated with the dyeing device generally designated by the numeral 5. Since the dyeing mechanism 5 is identical to dyeing mechanism 4, a detailed description thereofis not deemed necessary.

Similarly if more than a base color such as is applied by the unit 3 and two spaced applications of different colors as by the dyeing devices 4 and 5 are desired, it is only necessary to add in tandem relationship one or more units such as 4 and 5 to the arrangement as depicted in H65. 1 and 2 and additional colors may thus be applied.

While a particular embodiment of the invention has been shown and described, it will be understood that the invention is not limited thereto and that changes and modifications may be made without departing from the spirit and scope of the invention.

I claim:

1. Dyeing apparatus comprising a pair of movable printer units arranged intermittently to engage and dye a strand to be dyed, driving means for imparting operating movement to said printer units, separate coupling means interconnecting said driving means and each of said printer units control means interrelated with each of said coupling means and effective to impart relative movement to said printer units whereby the spacing between dyed portions of the strand is varied, each of said printer units comprising a rotatable driving head interconnected with said driving means and having a generally circular periphery, a rotatable idler head disposed in spaced coaxial relation to said driving head and having a generally circular periphery corresponding to the periphery of said driving head, at least one printer bar affixed adjacent its ends to the peripheries of said driving and idler heads, the driving head of each printer unit being disposedadjaccnt the idler head of the other printer unit and the driving and idler heads of each printer unit being arranged at opposite ends ofa common axis.

2. Dyeing apparatus comprising a rotary printer unit having at least one printer bar spaced from its axis of rotation at a fixed radius and disposed in generally parallel relation therewith and arranged intermittently to engage and dye a strand to be dyed, driving means for imparting rotation to said printer unit, drive wheels on said driving means and on said rotary printer unit, an endless element having a driving reach and a return reach and extending about each of said drive wheels and in nonslipping engagement therewith, a control block mounted for reciprocating movement in a direction transverse to both reaches of said endless element, a pair of follower elements mounted on said control block and disposed to engage said endless element in a nonslipping relationship scrambler elementh'aving a fixed axis of rotation adjacent and in transverse relation to the yarn and zigzag transverse portions disposed a'stridc' the yarn and engageable therewith to impart varying tension to the yarn and incremental longitudinal movement thereto so as to aid in varying the spacing between points of contact between the yarn and printer unit.

4. Apparatus according to claim 2 wherein said control block isinterconnected with said driving means through an eccentric driving device.

5. Dyeing apparatus comprising a pair of rotatable coaxial printer units arranged intermittently to engage and dye a strand to be dyed, each unit comprising a driving head and an idler head rotatably mounted on a common axis and in spaced coaxial relationship to each other and each of said units being disposed on a commonshaft, at least one printing bar affixed adjacent its ends to the peripheries of said driving and idler heads on each of said units one of said heads on each of said units being coaxially spaced between said heads of the other unit, driving means for imparting rotary movement to each of said driving heads, separate coupling means interconnecting said driving means and each of said driving heads, and control means coupled with said driving means and with at least one of said coupling means for imparting continuous relative rotary motion between each of said printer units, said control means being continuously operable in coordination with operation of said driving means.

6. Dyeing apparatus comprising a pickup roll, a printer unit spaced from said pickup roll and rotatable about a fixed axis generally parallel to the axis of said pickup roll and having a plurality of printer bars spaced about its center of rotation at a fixed radius from said axis and disposed in generally parallel relation therewith, a strand of yarn or the like movable between said printer unit and said pickup roll in a direction generally normal to said fixed axis and spaced therefrom, said rinter bars being sequentially engageable with said strand to orce said stran into engagement with said pickup roll, rotatable driving means for imparting rotating movement to said printer unit and to said pickup roll in opposite directions, coupling means including a flexible endless tension element directly interconnecting said driving means and said printer unit in a nonslipping relationship and having a driving reach and a return reach, and control means directly engageable with both reaches of said endless element and movable transversely thereof in coordination with movement of said driving means forvarying the effective lengths of said reaches relative.

to each other thereby to impart relative rotation to said printer .unit and said driving means. 

